Systems and methods for fruit and nut packing

ABSTRACT

A filling device for filling secondary containers within a primary container. The filling device includes a filling platform that includes a base and filling channels that are in fluid communication with the base. The filling channels are generally cylindrical in shape with a taper from a product entrance end proximal the corresponding opening to a distal product exit end. The taper changes the shape and/or reduces the dimension of the openings from the product entrance end to the product exit end of the filling channel. The filling device, with secondary containers attached thereto, is placed within a primary container and material is supplied to the filling platform in order to fill the secondary containers. When complete, the filling device is removed and the filled secondary containers remain within the primary container.

BACKGROUND

The present disclosure relates to systems and methods for filling at least two secondary containers within a primary container, and more particularly to systems and methods for filling at least two bags with product such as fruit and nuts within a box or other container.

Packages of items or material are often sold as individual packages. These packages are generally shipped to a sales point, such as a store, in larger containers, such as boxes. Hence, the bags must be filled and the bags placed in a shipping container.

An example of items sold at stores in bags and shipped to the stores in boxes is fruit. The individual bags must be filled with the fruit and the bags need to be shipped to the store. Thus, the fruit must be placed in the bags and the bags then placed in the shipping containers, which are typically boxes.

Generally, a total weight for the boxes is desired. Thus, the individual bags containing the fruit may have slightly varying weights, with the total weight of all bags substantially equaling the total desired weight for the shipping box. Often the individual bags are not sealed until they arrive at a store or other receiving location. Once received, the box is opened, the individual bags are weighed and marked and the bags may be sealed.

SUMMARY

In accordance with an embodiment of the present disclosure, a device for filling at least two secondary containers within a primary container includes a filling device that includes a base platform having at least two filling channels with the two filling channels each being in fluid communication with the platform through a corresponding opening defined in the base platform. In certain aspects, the at least two filling channels are generally cylindrical in shape and having a taper from a product entrance end proximal the corresponding opening to a distal product exit end. In certain aspects, the taper changes the cross-sectional shape and/or reduces the dimension of the openings from the product entrance end to the product exit end of the filling channel. In certain aspects, a secondary container includes a bag and a primary container includes a box. In accordance with another aspect of the present invention, the number of filling channels is in a range between two and thirty.

According to an embodiment, a device is provided for filling a plurality of secondary containers. The device typically includes a base platform having a floor with a plurality of substantially rectangular-shaped openings defined therein, and a filling channel extending from each of said plurality of substantially rectangular-shaped openings, wherein each filling channel tapers from a corresponding rectangular-shaped opening in the floor to a circular or oval shaped opening at a distal end of the filling channel. In certain aspects, the base platform includes up to four walls (e.g., one side wall, two side walls, three side walls or four side walls), each wall extending away from the floor in a direction away from the filling channels. In certain aspects, each wall extends away from the platform floor at an angle relative to a normal of the platform floor. In certain aspects, corners defined by each are sloped toward the openings. In certain aspects, each filling channel extends into a corresponding secondary container. In certain aspects, a corner defined by an opening is curved, and in certain aspects a corner is sharp.

In accordance with the present invention, a method of filling at least two secondary containers within a primary container includes engaging the secondary containers with filling channels of a filling platform, engaging a retention platform with the filling platform in order to retain the secondary containers in engagement with the filling platform, placing the filling platform and retention platform in the primary container and supplying the material to the filling platform such that the material moves into secondary containers through the filling channels.

In accordance with another aspect of the present invention, the method includes moving material along a conveyor belt to a supply station for supplying the material to the filling platform and moving the primary container to the supply station.

Reference to the remaining portions of the specification, including the drawings and claims, will realize other features and advantages of the present invention. Further features and advantages of the present invention, as well as the structure and operation of various embodiments of the present invention, are described in detail below with respect to the accompanying drawings. In the drawings, like reference numbers indicate identical or functionally similar elements.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S)

FIG. 1A is a top plan view of a filling device in accordance with an embodiment;

FIG. 1B is a side, cross-sectional view of the filling device of FIG. 1A, taken along the line B-B.

FIG. 2A is a top plan view of a filling device in accordance with an embodiment;

FIG. 2B is a side, cross-sectional view of the filling device of FIG. 2A, taken along the line B-B.

FIG. 2C is a perspective, cross-sectional view of the filling device of FIG. 2A, taken along the line F-F.

FIG. 3A is a top plan view of a filling device in accordance with an embodiment;

FIG. 3B is a side view of the filling device of FIG. 3A.

FIG. 3C is a side, cross-sectional view of the filling device of FIG. 3A, taken along the line B-B.

FIG. 3D is a blown-up view of a portion of FIG. 3A.

FIG. 4A is a top plan view of a filling device in accordance with an embodiment;

FIG. 4B is a side, cross-sectional view of the filling device of FIG. 4A, taken along the line B-B.

FIG. 4C is a side view of the filling device of FIG. 4A.

FIG. 4D is a blown-up view of a portion of FIG. 4A.

FIG. 5 is a schematic illustration of a filling system using a filling device in accordance with an embodiment.

FIG. 6 shows various views of a filling device including a rectangular opening tapering to a rectangular opening having a reduced dimension according to an embodiment.

DETAILED DESCRIPTION

In accordance with an embodiment of the present disclosure, a filling device 10 for filling secondary containers 11 within a primary container 12 (see FIG. 5) includes a filling platform 13. The filling platform includes a base or floor 15 and filling channels 16 in fluid communication with the base 15.

In an embodiment as shown in FIGS. 1A and 1B, walls 20 of the base of the filling platform 13 are sloped towards the openings 22 of the filling channels 16. Additionally, walls 20 of the filling platform 13 are also preferably curved and sloped at corners 21. Floor 15 provides a transition area from the filling platform 13, specifically a transition from walls 20 to the filling channels 16. The floor 15 includes a plurality of openings 22 defined therein. Each opening 22 generally has a rectangular shaped profile (e.g., square or rectangular), but may have a circular or curved (e.g., oval-like) shape. In the embodiment as shown in FIGS. 1A and 1B, each opening 22 may have corners 23 that may be curved and/or sloping to facilitate product (e.g., fruit, nuts, etc.) entering corresponding filling channels 16.

In an embodiment, the filling channels 16 are generally cylindrical in shape and thus, are essentially tubes. In certain embodiments, the cross-sectional shape (e.g., cross-sectional shape perpendicular to an axis of the filling channel) changes from the entrance end at the corresponding opening 22 to the exit end distal from the opening 22. For example, as shown in FIG. 1B, the cross-sectional shape may change from generally rectangular (e.g., rectangular walls with curved corners) at the entrance end by the opening 22 to substantially oval or elliptical at the exit end of the filling channel. Also, in certain embodiments, the dimension of the filling channel will reduce from the entrance end proximal the opening 22 to the exit end, such that the filling channel tapers. This can be seen in the top down view of FIG. 1A, as well as the side view of FIG. 1B which shows the reduced opening dimension 17 of the opening at the exit end along the B-B line of FIG. 1A. FIG. 2C shows a more dramatic taper and reduced dimension 17 of the opening at the distal end relative to the opening end for a cross section taken along line F-F of FIG. 2A. It should be noted that device 10 of FIG. 2A-2C is similar to device 10 of FIG. 1A-1C, but has a different orientation of taper along the filling channels 16 (i.e., oval cross-sectional openings at exit end are oriented 90° relative to each other).

In certain embodiments, the cross-sectional shape remains the same from the entrance end at the corresponding opening 22 to the exit end distal from the opening 22, with or without a taper (reduction or change in dimension from the opening 22 to the exit end distal from the opening 22). Additionally, for a rectangular shaped opening, or end, the rectangle shape may have corners 23 that are soft/rounded such as shown in FIG. 1A, or the corners 23 may be sharp, e.g., having an angular corner. FIG. 6 shows various views of an example of a filling device including filling channels that have a rectangular cross-sectional shape from the entrance end at the corresponding opening to the exit end distal from the opening, with a taper (e.g., reduction in dimension) according to an embodiment.

Those skilled in the art will understand that the filling platform may include as many filling channels as desired. In exemplary embodiments illustrated in the drawings, there may be twelve (12) filling channels (FIGS. 1 and 2) or there may be eight (8) filling channels (FIGS. 3 and 4). In certain aspects, there are between two and thirty filling channels. The dimensions of the filling device may vary as needed. In certain specific embodiments, for example, the width of the device may be between about 18 or 19 inches, or longer or shorter, the length of the device range from about 19 inches to about 26 inches or longer or shorter, a length of the filling channels 16 may range from about 3 or 4 inches to 8 inches or longer, and a height of the sidewalls 20, where present, may range from about 2 to 3 inches or longer. Hence, a height (h) (see, e.g., FIG. 1B) of the device may range from about 4 inches to about 11 or 12 inches or longer. A radius defined by soft filling channel corners 23 is approximately 2 to 3 inches while the shape and dimension of the exit end of the filling channels may be approximately circular with a diameter of from about 2 inches to 4 inches or greater, or the shape may be substantially oval or elliptical as shown in FIGS. 1 and 2 with a dimension ranging from about 2 inches to 3 inches or greater for the semi-minor axis of the ellipse and about 4 inches to 6 inches or greater for the semi-major axis of the ellipse. Other shapes/dimensions may be used. In FIGS. 3 and 4, for example, the filling channel may taper from a rectangular shaped opening in floor 15 to a substantially parallelogram-type shape as shown in FIGS. 3A and 3D. The exit end may have soft, curved corners 28 as shown in FIGS. 3A and 3D, or the corners may be sharp, or a combination of curved and sharp corners.

FIG. 4 shows another embodiment including a retention lip 30 at the exit end of the filling channels 16. Retention lip 30 may include a flared tip as shown in FIG. 4B, where the filling channel tapers down and the tapers back out slightly. The retention lip advantageously facilitates retention of a secondary container, e.g., bag, on the filling channel as the retained secondary container is being filled with product through the filling channel. For example, the retention lip 30 may prevent slippage of the secondary container 11 as product fills the secondary container and the weight of product in the secondary container increases—in this case the secondary container may slip down the filling channel, yet be retained by the retention lip, so as to optimize the amount of product filling the secondary container. The retention lip may be present in embodiments including a tapered channel 16, such as shown in FIG. 4B, and they may be present in embodiments with no taper to the channel 16.

In certain embodiments, the filling device is made of lightweight rigid or semi-rigid materials such as plastic or resin material. It is desirable that the filling device be made of, or coated with, food grade materials, such as food grade plastic material (e.g., PVC or polypropylethylene) or other material as would be understood by one skilled in the art. Preferably a filling device is made of a single piece of material, e.g., formed by a plastic molding process or similar process, or by two or more pieces that are attached and which remain attached during a filling process.

In use, before a filling device 10 is placed in a primary container 12, a secondary container 11, in this example, a bag, is placed on one or more or all of the filling channels 16. The shape and dimension of the filling channels is such as to hold the bags sufficiently snugly against the filling channels. The dimension of the exit end can be tailored to substantially match that of the opening of the secondary container, so as to facilitate application and retention of the opening of a secondary container on the exit end of a filling channel, without undue exertion needed for the secondary container to be detached from the filling channel. The filling device is then placed into the primary container.

The primary container may then be moved to a supply station so that the bags can be filled with material. In an embodiment, a filling device is used to automatically fill the bags with product such as fruit or nuts. As can be seen in FIG. 5, primary containers 12, such as boxes, including filling devices 10 are moved along a conveyor 30 to a supply station 31 such that the primary containers are under a second conveyor 32. Product is then moved along the second conveyor 32 dropping off the end of the conveyor 32 at the supply station 31 and into the filling device. The product then falls into the filling channels and thus into the secondary containers.

Preferably, the total weight within the shipping container is the desired weight and thus, each secondary container does not require the same weight of product therein. Thus, once the shipping container has received the proper weight of product (fruit, nuts, etc.), the filling device is removed from the shipping container leaving the filled bags in the shipping container. In certain aspects, the filling device may be retained and shipped within the primary container. Bags may then be sealed as desired. However, often the bags are left unsealed and upon arrival of the shipping container at the ultimate receiving location such as a selling point (e.g., a grocery store or fruit and nut stand), the bags are removed from the shipping container, and are weighed and may be sealed, with the weight marked thereon.

The present embodiments are useful for filling secondary containers within a primary container, especially for filling product such as fruit or nuts in bags that are shipped within a shipping container or box. The filling device is generally, but not necessarily, used in conjunction with an automatic box filler that is commonly used in the packing industry to fill boxes of various sizes and weight. FIG. 5 illustrates an example of such an automatic box filler.

The filling device is capable of rapidly filling bags held by the device such that the preset weight desired by the packer for the shipping container may be realized quickly. Since it is often not necessary that each bag have a prescribed weight in it and that the master container merely needs to have a prescribed weight, the filling device facilitates rapid filling of secondary containers within a primary container.

All references, including publications, patent applications, and patents, cited herein are hereby incorporated by reference to the same extent as if each reference were individually and specifically indicated to be incorporated by reference and were set forth in its entirety herein.

The use of the terms “a” and “an” and “the” and “at least one” and similar referents in the context of describing the disclosed subject matter (especially in the context of the following claims) are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. The use of the term “at least one” followed by a list of one or more items (for example, “at least one of A and B”) is to be construed to mean one item selected from the listed items (A or B) or any combination of two or more of the listed items (A and B), unless otherwise indicated herein or clearly contradicted by context. The terms “comprising,” “having,” “including,” and “containing” are to be construed as open-ended terms (i.e., meaning “including, but not limited to,”) unless otherwise noted. Recitation of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range, unless otherwise indicated herein, and each separate value is incorporated into the specification as if it were individually recited herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or example language (e.g., “such as”) provided herein, is intended merely to better illuminate the disclosed subject matter and does not pose a limitation on the scope of the invention unless otherwise claimed. No language in the specification should be construed as indicating any non-claimed element as essential to the practice of the invention.

Certain embodiments are described herein. Variations of those embodiments may become apparent to those of ordinary skill in the art upon reading the foregoing description. For example, it is contemplated that some of the openings 22 may not have a corresponding filling channel 16. The inventors expect skilled artisans to employ such variations as appropriate, and the inventors intend for the embodiments to be practiced otherwise than as specifically described herein. Accordingly, this disclosure includes all modifications and equivalents of the subject matter recited in the claims appended hereto as permitted by applicable law. Moreover, any combination of the above-described elements in all possible variations thereof is encompassed by the disclosure unless otherwise indicated herein or otherwise clearly contradicted by context. 

1. A device for filling a plurality of secondary containers, the device comprising: a base platform having a floor with a plurality of substantially rectangular-shaped openings defined therein; and a filling channel extending from each of said plurality of substantially rectangular-shaped openings, wherein each filling channel tapers from a corresponding rectangular-shaped opening in the floor to a circular or oval shaped opening at a distal end of the filling channel.
 2. The device of claim 1, wherein the base platform includes up to four walls, each wall extending away from the floor in a direction away from the filling channels.
 3. The device of claim 2, wherein each of the up to four walls extends away from the platform floor at an angle relative to a normal of the platform floor.
 4. The device of claim 2, wherein corners defined by the up to four walls are sloped toward the openings.
 5. The device of claim 1, wherein each filling channel extends into a corresponding secondary container.
 6. The device of claim 1, wherein corners defined by each of the substantially rectangular-shaped openings are curved.
 7. The device of claim 1, wherein a number of the plurality of filling channels is in a range between two and thirty.
 8. A device for filling a plurality of secondary containers, the device comprising: a base platform having a floor with a plurality of openings defined therein; a filling channel extending from each of said plurality of openings, wherein each filling channel tapers or transitions from a corresponding opening having a first shape proximal the floor to a second shape proximal a distal end of the filling channel, wherein a) the first shape is different than the second shape or b) the first shape has a same shape as the second shape and the second shape has a reduced dimension relative to the first shape.
 9. The device of claim 8, wherein the base platform includes up to four walls, each wall extending away from the floor in a direction away from the filling channels.
 10. The device of claim 9, wherein each wall extends away from the platform floor at an angle relative to a normal of the platform floor.
 11. The device of claim 9, wherein corners defined by the up to four walls are sloped toward the openings.
 12. The device of claim 8, wherein each filling channel extends into a corresponding secondary container.
 13. The device of claim 8, wherein the first shape is substantially rectangular shaped and the second shape is substantially circular or oval or elliptical.
 14. The device of claim 8, wherein the first shape and the second shape are both circular or oval or elliptical.
 15. The device of claim 8, wherein corners defined by the opening are curved.
 16. The device of claim 8, wherein a number of the plurality of filling channels is in a range between two and thirty.
 17. A method of filling a plurality of secondary containers within a primary container, the method comprising: providing a filling device comprising a base platform having a floor with a plurality of openings defined therein, and a filling channel extending from each of said plurality of openings, wherein each filling channel tapers or transitions from a corresponding opening having a first shape proximal the floor to a second shape proximal a distal end of the filling channel, wherein a) the first shape is different than the second shape or b) the first shape has a same shape as the second shape and the second shape has a reduced dimension relative to the first shape; securing a secondary container to one or more of the filling channels; placing the filling device with the secured secondary containers adjacent the primary container; and filling the secondary containers with product through the filling device.
 18. The method of claim 17, further comprising separating the filled secondary containers from the filling device.
 19. The method of claim 17, wherein the secondary containers include bags and wherein the primary container includes a box or a shipping container.
 20. The method of claim 17, wherein the product includes fruit or nuts. 